replogle



l. B. REPLUGLE.

SPARK COIL AND METHD 0F MAKING SAME.

APPLICATION FILED NOV.25| 1916.

Patented Feb. 8,1921.

2 SHEETS-SHEET i.

J. B. REPLOGLE.

SPARK COIL AND METHOD 0F MAKING SAME.

APPLICATION FILED Nov. 25, 191e.

1,367,988. muted Feb. 8,1921.

2 SHEETS-SHEET 2.

E3 IS T M IVIV Ei I III 30 5 noauto@ 90 mea 35% @Wou/m21? S W MWI/(16x @vvd/I #FW 4taken at right angles to the -UNITED STATES PATENT OFFICE.

JAMES B. REPLOGLEKOF DETROIT, MICHIGAN, ASSIGNOR TO 'REMY ELECTRIC COM- PANY, 0F ANDERSON, INDIANA, A CORPORATIONF INDIANA.

SPARK-COIL AND METHOD OF MAKING SAME.

Specification of Letters Patent.

Patented Feb. 8,v 1921.

Application ld November 25, 1916. Serial No. 133,483.

To all whom t may concern:

Be it known that I, JAMES B. REPLOGLE, a citizen of the United States, residin at Detroit, in the county of Wayne and tate of Michigan, have invented certain new and useful Improvements in Spark-Coils and Methods of Making Same, of which the following is a full, clear, and exact description.

This invention relates to certain new and useful improvements in spark coils, and has for its objects the provision of,a coil which produces an efficient spark with a minimum of current. The construction is also such that the amount of winding is materially reduced over previous constructions and the cost of manufacture is thereby materially decreased.

- The present invention also relates to improved methods of manufacturing coils, and

these methods will be more explicitly pointed out hereafter. C

The invention also relates to certain details of construction and 'arrangements of parts which will be more fully described in the specification shown in the accompanying drawings, and more particularly pointed out 1n the appended claims.

v In the drawings:

Figure l shows an proved coil, the casing being shown in section.

Fig. 2 is a top plan view of the coil, and shows ythe arrangement of the terminals.

Fig. 3 is a sectional elevation view being view shown in Fig. 1.

Fig. 4 is`a .sectional view taken on line Fig. 1. l l

Fig. 5 is a diagrammatic view showing the relatlon of the primary and secondary windings to the laminated core pieces andshowing in connection herewith an ignition circuit. The spark coil is particularly adapted for such use, lbut it is to be understood that it. may be used for other purposes than igmtion. e

Fig.r 6 is a detail view of a modified core construction.

Fig. 7 is a detail view of another modified core construction. f

The present invention comprises broadly the usual primaryand secondary; windings disposed coagiallyjwith respect toyeach other and preferably having the secondary outside elevation of my ima vmoved from the interstices of the coils.

karranged in sets, each set having one branch extending upwardly within the windings and having another branch extending upwardly outside of the windings. The yokes of the U-shaped pieces vconnect the inner and outer branches at the bottom thereof, as

shown in Figs. 1, 5 and 7:t windings.

The primary winding 10 is wound upon akpaper tube 11, and thereafter Ithe secondary windingy 12 is wound thereon. The secondary winding is made of a number of layers of fine wire,l each succeeding layer being--insulated from the adjacent layer in any desired manner, as by a layer of paper 14C. 'Ihe primary extends slightly above the secondary winding, as shown. After the winding of the secondary has. been c'om- `plted the outer end of the secondary wire. is fastened to a pointed tack 15. A number,

of layers of paper 16 are then wound around and outside of the secondary, the tack successively perforating each layer of paper during the winding operation. Just before one ofthe last layers of paper perforates the tack a mica Washer 17 is placed over the tack. 'Ihevpaper winding is then completed covering the washer. The tack now affords a convenient meansmof attaching a secondary lead which can be done by soldering a wire to the tack. The micawasher serves to anchor the tack more rigidly in the paper insulation at the outside of the coil, and protects the underlying layers against charring during the above mentioned soldering operation.

In winding the coil the inner end of the vsecondary is brought out at the bottom adjacent the fiber tube 11, as shown at 18, and the primary leads are brought out at the top at 19 and 20. When the winding of the paper layers 16 has been completed, a fiber r-up 21 is placed over the bottom of the coil, The wound coils are then placed in a vacuum impregnator and a vacuum is maintained until all the air and moisture have been rehe'ated insulating compound is then vdrawn into'the impregnator by vacuum. This heatably of insulating material) may be ed compound is of such character that it has relatively low viscosity at high temperatures and which solidiiies by a graduatincrease of viscosity rather than by crystallization from a mother liquid. As an ,example ot such a substance, l may mention a mixture of 15% beeswax and 35% rosin. |The liquid when turned in on the coils is heated to such a point that it has a low viscosity. rlhe impregnator is kept closed and pressure is applied and the temperature of the liquid is kept high until the thin compound has filled all the interstices in the coils. rlhe temperature is then decreased until the viscosity of the insulating compound has increased to such an extent that the coils may be safely withdrawn without having the insulating liquid run out. The coils are then ready for complete assembly with the cores within the casing.

Coffe construct/0a.

As previously stated in brief at the opening paragraph of the specification, the core comprises in its preferred form a number ot stamped U-shaped pieces or laminae. These pieces have lower or yoke portions and branches 31 and 32. A number of the llshaped pieces are grouped together, and the set A thus formed is slid into position with branches 31 inside the fiber tube 11 and branches 32 outside the outer layer of paper covering the secondary winding. A second set of core pieces B is then slid into position with branches 31 inside and branches 32 outside the windings. The assembly of core pieces and coil is then ready to be placed in the casing. This casing comprises an open ended ber cylinder 35, which cylinder is capped at its upper end by a metallic cover plate 33, having binding terminals 37 and 38 and a rheostat or resistance l() thereon.r

This cover plate is provided with bosses l1 to attach the coil to any frame or fined part. rlhe cover plate 36 is apertured to receive a threaded rod 4t2.' rllhis rod ypasses through space between the branches 31 of the two sets of core pieces A. and B, as shown in Figs. 3 and et, and passes through a hole in a bottom plate e3 and into a nut 44. as shown. By tightening down nut a washer i6 (preferclamped down tightly on the tops of the branches 31 of the core pieces. 1n this ymanner'the core and the windings may be securely held in place in the casing, and luy-tightening nut l? the top/cover plate may be held in position against the top of the casing 35. By locating .the holes in the cover and bottom plates which receive 'the rod l2 ofi' center, the coil and core willbe supported within the casing 35 at one side thereof. This provides space within the Ycasing to receive a con-` denser (see Figs. 3 and 4). This condenser may be curved to conform to the conactress tour of the casing. The core described posesses several advantages over a core composed of E-shaped laminae, in that the core composed of lJ-shaped lamin may be manufactured with less waste of material. IThe two sets of U-shaped laminee may be spaced apart to provide space for the central bolt 4:2 which secures the sets of lamin together in position within the coil casing and which also secures the parts of the casing together; and the sets of lamin may be arranged so as to conform substantially to the cylindrical surface of the coil, whereby to conserve space. This arrangement would not be possible with a single set of l-shaped laminee.' y

It will be'l noted that the primary and secondary windings are less in height than the branch portions 31 and 32 of the cores A and B, that is, the distance between the ends of these coils when formed is less than the length of the branch portions. It will be noted that the coil windings 10 and 12 are located nearer to the yoke portions 30 of the cores A and B than to the outer free ends of these branch portions. Locating these coils in this manner causes the turns of the coils to be surrounded by as large a number of lines of magnetic ux as possible. However, these coils should be separated from the yoke portions sufficiently to minimize the possibility of a short circuit, particularly oi the secondary winding.

Primary leads 19 and 2O are then connected to the terminals 37 and 33 on the top plate; secondary lead 18 and wire 52 leading to one side of the condenser are brought out or" the casing and grounded on the bottom plate 43; a secondary lead 53 is attached to the tack 17 and attached to a binding post 5d: on the outside of the casing. Une condenser lead is attached to a binding post on the top of the casing.

The connections to the various coils will be clearer by referring to F ig. 5. .Here 'l represents a timer from the grounded side of'y which wire 52 leads to the condenser 50. The other side of the timer is connected through resistance 40 to the primary 10, which has connected thereto the grounded battery C. @ne side of the secondary 12 is grounded and the other end is connected to the usual distributer D leading to the spark plugs S.

Fig.l 7 shows another modilication in which the branches 32b and 31b arebent into planes parallel with each other.

l 1t is understood that my invention is susceptible of various modifications, as will occurto those skilled in the art. What l claim as my invention is more particularly pointed out in the appended claims.

I claim:

1. A spark coil comprising a core hav-` ing branch portions anda connecting yoke memes of the branch portions, said windings being less in length when formed than the height of the branch portions, and located nearer to the yoke portion lthan to the outer free ends of the branch portions; said branch portions being separated beyond the windings whereby to provide an air gap outside of said windings.

2. A spark coil comprising a plurality of U-shaped laminated core members each having branch portions and a connecting yoke portion; and coil windings surrounding adjacent branches of said core members and being less in height when formed than the height of the branch portions7 and located nearer to the said yoke portion than to the free outer ends of the branch portions; said branch portions being separated beyond said windings whereby to provide an air gap outside of said windings.

3. The herein described method of making spark coils, which consists in winding the secondary winding of the coil in the usual manner, attaching a pointed tack to the end of the winding and then winding a plurality of layers of material outside the coil in such a manner as to cause the tack to successively perforate the said layers of material during the winding operation.

4. A spark coil having concentric primary and secondary windings, a plurality of layers of insulating material outside the secondary winding, a tack perforating the said layers and connecting with the end of the secondary winding, said tack forming a terminal to which a lead may be attached at the outside of the said layers of insulating material.

5. A spark coil having concentric primary and secondary windings, a plurality of layers of insulating material outside the secondary winding, a terminal extending from the end of the secondary winding radially through the layers of insulating material and having a mica washer embedded in the layers of materialand associated with the terminal to aid in anchoring the same in the insulating material.

6. A spark coil comprising concentrically disposed primary and secondary winding, a core therefor having U shaped core pieces, a casing comprising a cylinder member having a base secured thereto, a cover plate adapted to coperate with the cylinder, and a rod extending from base plate to cover within the casing and having provsons for retaining the core pieces in position upon the base plate, and the cover upon the cylinder.

7. A spark coil including a core comprising a plurality of sets of superimposed U- shaped laminae; primary and secondary windings surrounding adjacent branches of said sets of U-shaped laminas; a casing; and a common means adapted to secure both sets of laminas in correct relation to each other and in fixed position upon a portion of the casing.

8. A spark coil including a core comprising a plurality-of sets of superimposed U- shaped laminas, the adjacent branches of said U-shaped laminas being spaced apart; primaryand secondary windings surrounding the said adjacent branches of the sets of' U-shaped laminae; a casing including a cylindrical member and base secured thereto and a cover adapted to coperate with the cylindrical member; a rod having threadedend portions extending through the base member and the cover member of the casing, and between the adjacent branches of the core sets; nuts engaging the threaded portions of the plate to secure the cover member in position upon the cylindrical member; and a washer and a threaded nut engagingthe plate and adapted to coperate with one of the first mentioned nuts to secure the core in position upon the base member.

9. A spark coil including a core comprising U-shaped core members; coil windings surrounding adjacent legs of said core members; a casing having a supporting portion; and means for securing both core members in xed position upon the said supportlng portion of the casing, and in correct relation to each other.

10. An induction coil comprising a core having branch portions and a connecting yoke portion; and a winding 1n inductive relation to said core, said winding being less in height than the height of the branch portions of the core, and located nearer to the yoke portion of the core than tothe outer free ends of said branch portions; said branch portions being separated beyond the windings whereby to provide an air gap outside of said windings.

In testimony whereof I aliix my signature.

JAMES B. REPLOGLE. 

